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-Welding stainless to mild steel shouldn't be a problem, IF you use the correct filler material and technique. 309L filler rod is normally the filler rod of choice when welding stainless to mild steel. Using mild steel filler rod on stainless, or certain types of stainless filler rods on mild steel, causes dilution of the chromium and results in a brittle weld(usually resulting in a small crack), while 309L has extra high chromium to reduce this.
-For the thickness of that tubing and size of that fitting, the weld looks a little too big and too hot. Excessive heat leads to greater stresses and chance of cracking and warping. Too hot of a weld also pulls in more contaminants, especially from the back side of the weld.

-Welding stainless to mild steel shouldn't be a problem, IF you use the correct filler material and technique. 309L filler rod is normally the filler rod of choice when welding stainless to mild steel. Using mild steel filler rod on stainless, or certain types of stainless filler rods on mild steel, causes dilution of the chromium and results in a brittle weld(usually resulting in a small crack), while 309L has extra high chromium to reduce this.
-For the thickness of that tubing and size of that fitting, the weld looks a little too big and too hot. Excessive heat leads to greater stresses and chance of cracking and warping. Too hot of a weld also pulls in more contaminants, especially from the back side of the weld.

Thanks for the advice Miles.

An odd question, but what did you do with the windshield washer system?

Quote:

Originally Posted by 0-60motorsports

Man that sounds wicked. Congrats.

Thanks Ejaz

Quote:

Originally Posted by ritos530i

Nice work Adam

You're alive!

Thanks Rito

Quote:

Originally Posted by Commanderwiggin

Houston...we have lift-off!

I will admit if felt that way when it first started.

Quote:

Originally Posted by STORMER

Wow. Project of years. Have you been driving it at all during this time? Or intermittantly in small intervals?

I wish....last time I drove this car was Sept. 2010. I'm getting really excited to drive it again...

An odd question, but what did you do with the windshield washer system?

I was young, I had a lot of bad ideas, I took out the washer fluid tank thinking it'd save weight, made a jumper to plug into the level switch connector to make the car not show a low washer fluid light, and tucked the wiring away. I think all the electrical should still be there.

By the looks of it, it looks like I also took out the sprayers and hose that went with it too.

As for where it went, after it was removed, I'm not quite sure. I can check if it's on a shelf somewhere if you want.

I was young, I had a lot of bad ideas, I took out the washer fluid tank thinking it'd save weight, made a jumper to plug into the level switch connector to make the car not show a low washer fluid light, and tucked the wiring away. I think all the electrical should still be there.

By the looks of it, it looks like I also took out the sprayers and hose that went with it too.

As for where it went, after it was removed, I'm not quite sure. I can check if it's on a shelf somewhere if you want.

I'm pretty sure I was the bad influence that initiated the Windshield washer delete mod. I went pretty nuts with the 330Ci....at one point it was down to less than 2700 lbs w/o driver or fuel.

I have the washer tank and pump(s) from the 330Ci, but I don't have any of the lines or nozzles. If you could check, it would be much appreciated, as I am looking to re-install all of these parts.

Did the dual cooler approach with hood venting cause too many clearance issues?

I think it was feasible, but I just didn't have the time to fabricate it. The EGR pump, and windshield washer tank would need to be relocated on the passenger side, which would be fairly complicated.

I've had to drop a number of ideas for the time being to accelerate the running timeline. Lots of these things could be done at a later time, if the existing solutions proved to be ineffective.

Something else to consider is that this was meant to be a car that I would drive while building my next project car to replace the 330Ci. The ideas for that are really radical, so I have to pick my battles regarding time spent developing ideas.

Half way around the world (in the middle of a class) and I'm still following along and jumping forums to see this build! Great job Adam looks great and as always love the way you put everything together especially with the trans-cooler bracket in the bumper support.

Half way around the world (in the middle of a class) and I'm still following along and jumping forums to see this build! Great job Adam looks great and as always love the way you put everything together especially with the trans-cooler bracket in the bumper support.

Yup...you are exactly half way around the world from me. (11,700km)

Honestly, the trans cooler bracket is more a matter of convenience in fabrication than functionality. If I was to do it again, I would probably build the bracket into the radiator support assembly, so that the bumper support can be unbolted easily.

For those that wondered why I didn't paint the entire bumper: There may be more changes to it in the middle and on the passenger side in the future.

Also, some may note that I haven't finished connecting the CCV. There is still some work in that area that I haven't got to yet....just waiting on some more electronics to arrive before I finalize how I'm going to do it.